MP5-76105 datasheet, PDF - EEWORLD Datasheet

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MP5-76105: DescriptionMultichip Packages MEGA-PFC, 5 OUTPUTS; Categorysemiconductor Memory IC Multichip packaging; File Size1MB，32 Pages; ManufacturerVICOR; Websitehttp://www.vicorpower.com/

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Multichip Packages MEGA-PFC, 5 OUTPUTS

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USER GUIDE | UG:119

PFC MegaPAC-EL

PFC MegaPAC-HPEL

Power Factor Corrected AC-DC Switchers

Contents

Overview

Standard Features

Optional Features

Mechanical Considerations

MegaPAC Dos and Don’ts

Technical Description

Configuring and

Reconfiguring MegaPACs

ConverterPAC Functional

Description

Part Numbering

Page

ConverterPAC Output and

Connector Pin Identification 10

PFC MegaPAC-EL and -HPEL

Quick Install Instructions

PFC MegaPAC-EL and PFC

MegaPAC-HPEL

Mechanical Drawing

Interface Connections

Specifications

Output Studs

Output Power Derating

PFC MegaPAC-EL/HPEL

Connector Kit (19-130040)

Listing

Overview

The PFC MegaPAC-EL and PFC MegaPAC High Power Low Noise (HPEL) combine power factor

correction (PFC) with the configurability of the MegaPAC family of power supplies. The

PFC MegaPAC-EL and PFC MegaPAC-HPEL provide up to 1,600W and 2,400W of output power

respectively and have power densities of 4.3W/in

and 6.5W/in

respectively. The chassis has eight slots

and can provide as many as 16 outputs. The PFC MegaPAC-EL and PFC MegaPAC-HPEL have the same

input and output connections, mounting points and the same dimensions: 3.4 x 6.0 x 15.6in

[85,6 x 152,4 x 396,2mm]. Note that length of older units were 15.5in [393,6mm].

A complete power supply is configured at the factory by selecting and inserting up to eight (four – six

for the PFC MegaPAC-HPEL depending on ConverterPACs used) same length slide-in output assemblies

called ConverterPACs. ConverterPACs™ incorporate one or two VI-200™ / VI-J00™ and / or Maxi Vicor

DC-DC converters and are available in a wide selection of output voltage and power levels. The net

result is a power supply that offers the advantages of a custom supply, but is assembled from standard

and modular building blocks.

Manufactured at Vicor, the entire family of MegaPAC power supplies is completely user-configurable.

If output requirements change, i.e., more power or a different output voltage is needed, upgrading

is easy: simply unlock a single screw and replace the slide-in ConverterPAC assembly with one that is

of the same length and has the desired voltage power rating. For additional flexibility, ConverterPACs

can be connected in parallel to increase output power (booster ConverterPACs), or in series for

higher voltages (total output voltage should not exceed 400V). The driver is to the left of the

boosters when looking at the output end of the supply. A user-friendly interface provides control and

output sequencing capability (see Page 16 for more information about this capability), in addition to

useful status indicators. Please consult our Applications Engineering Department if you have other

special requirements.

Connector Kit for

Dual Outputs only -

MegaPAC Family 19-130042 24

Current Share Boards -

Optional Feature

Current Share Boards -

Optional Feature Diagram

Output Sequencing

Note: This user guide contains references to parts and products that are no longer available for new designs.

They remain included for reference only.

UG:119

Page 1

Mechanical Considerations

The PFC MegaPAC-EL™ and PFC MegaPAC-HPEL™ can be mounted on any of four surfaces using

standard 8-32 or 4mm screws. The chassis comes with four mounting points on each surface; maximum

allowable torque is 20lb.in. The maximum penetration is 0.15in [3.8 mm].

When selecting a mounting location and orientation, the unit should be positioned so air flow is

not restricted. Maintain a 2in minimum clearance at both ends of the PFC MegaPAC-EL and PFC

MegaPAC-HPEL and route all cables so airflow is not obstructed. The standard unit draws air in at the

fan side / AC input side and exhausts air out the load side. If airflow ducting is used, use caution, as

sharp turns could present back pressure to the PFC MegaPAC-EL and PFC MegaPAC-HPEL. The fan

moves approximately 30CFM of air.

Avoid excessive bending of output power cables after they are connected to the PFC MegaPAC-EL

and PFC MegaPAC-HPEL. For high-current outputs, use cable ties to support heavy cables in order to

minimize mechanical stress on output studs. Be careful not to short-out to neighboring output studs.

The PFC MegaPAC-EL and PFC MegaPAC-HPEL units are supplied with serrated, flanged hex-nuts on all

output studs. Therefore, thread-locking compounds or lock washers are not required. The maximum

torque recommended on flanged nuts is 45lb.in. Never loosen the inner nut on a ConverterPAC™. This

nut supports the hardware inside the ConverterPAC and is factory torqued.

Avoid applications in which the unit is exposed to excessive shock or vibration levels. In such

applications, a shock-absorption mounting design is required.

MegaPAC™ Dos and Don’ts

units without Autosense, do not leave ConverterPAC Sense lines open. Always terminate them to

For

their respective output locally or at the load. Use twisted pair 22-24AWG wire. If ConverterPAC has

Autosense, no local-sense connection is required. See Pages 11 and 12 for more information

on Autosense.

needed, use Connector Kit # 19-130040 for the PFC MegaPAC-EL and PFC MegaPAC-HPEL.

Always fill all output slots of the MegaPAC. If a slot is not filled with a ConverterPAC, it should be

filled with an airblock. Airblocks are plastic assemblies whose main function is to fill up an empty slot.

Any airflow escape from an empty slot significantly degrades thermal performance and can result in

overheating and damage to the power supply.

Always turn the power supply off before disconnecting input or output wires.

NEVER disconnect the +Out and –Out load wires while the supply is operating, as disconnecting WILL

cause damage to the power supply.

not unplug ConverterPACs while input power is applied. They are not designed for

hot-plug applications.

not restrict airflow to the unit. The cooling fan draws air into the unit and forces it out at the

output power terminals.

UG:119

Page 3

power expansion, use booster ConverterPACs™. Viewing the unit from the output terminal side,

For

always insert boosters to the right side of the driver.

not use boosters as independent outputs. Disconnecting bus bars will damage

booster ConverterPACs.

booster arrays, do not remove bus bars.

For

Always ensure that output hex-nuts are properly torqued before applying power to supply.

the output (+/–) power cables next to each other to minimize inductance.

Run

Wait five minutes after shutting off power before inserting or removing ConverterPACs.

MegaPACs does not have user serviceable components. They must be returned to the factory

The

for repairs. Contact Customer Service for a RMA number before returning the unit. Do not attempt

to repair or modify the power supply in any manner other than the exchange of ConverterPACs as

described in this Design Guide.

Insert proper fault protection at power supply input terminals (i.e., a fuse).

proper size wires to avoid overheating and excessive voltage drop.

Use

Never loosen the inner nut on a ConverterPAC.

Verify output nuts are tight before powering up.

FinQPACs™ require two slots each because of the larger heat sink attached to dissipate the extra

heat generated by the higher-power Maxi module. Refer to Page 8 for more information on which

ConverterPACs can be used.

Technical Description

The PFC MegaPAC-EL™ and PFC MegaPAC-HPEL™ chassis consists of an offline single phase,

power-factor-corrected front end, EMI filter, cooling fan, low-noise filters, customer interface and

associated housekeeping circuits. Input AC mains voltage (L1, L2 and GND) is applied to a terminal

block. The input current is passed through an EMI filter designed to meet conducted noise limit A

specifications of FCC Part 15, VDE 0871 and EN55022 Class A. At start up, inrush current is limited by a

PTC thermistor. The PTC is shunted out shortly after initial power up by a DC bus voltage Sense circuit

driving a relay. After rectification, the input voltage is put through a boost converter that keeps the AC

input current sinusoidal and synchronized with the AC input voltage (in compliance with EN61000).

The boost converter delivers regulated high voltage DC to the hold-up capacitors and backplane.

The backplane supplies power to a variety of ConverterPAC assemblies that provide the desired

regulated outputs.

Voltage conversion in the output assemblies is achieved by the Vicor family of Zero-Current Switching

(ZCS) DC-DC converters. These are forward converters in which the main switching element switches

at zero current. This patented topology has a number of unique attributes: low-switching losses;

high-frequency operation resulting in reduced size for magnetics and capacitors; excellent line- and

load- regulation; wide-adjustment range for output; low EMI / RFI emissions and high efficiencies.

At initial power up, the PFC MegaPAC-EL and PFC MegaPAC-HPEL outputs are disabled to limit the

inrush current and to allow the DC bus potential to settle out to the correct operating level.

A low-power flyback converter operating with PWM current-mode control converts the high-voltage

DC bus into regulated low voltage to power the internal housekeeping circuits and DC cooling fan. The

internal housekeeping V

comes up within two seconds after the application of input power. Once the

high-voltage bus is within its limits, the AC OK signal asserts to a TTL “1” indicating the input power is

OK and enables the power outputs. An auxiliary V

output of 5V

sourcing up to 0.3A is provided for

peripheral use.

UG:119

Page 4

An output Enable / Disable function is provided by using an optocoupler to control the Gate In pins

of the ConverterPAC™ assemblies. If the Enable / Disable control pin is pulled low, the optocoupler

turns on, pulling the Gate In pin low and disabling the ConverterPAC output. The nominal delay for an

output to come up when measured from release of the Enable / Disable pin is 10 – 15ms. The General

Shutdown function controls all outputs simultaneously and works in a similar manner.

The ride-through (hold-up) time is the amount of time the load can be supported before loss of output

regulation after the loss of input power. Detecting the loss of input power takes a finite time period

after which the AC Power OK signal goes from a TTL “1” to “0." This signal is available for use within

1.2s after initial power up and can be used to indicate an impending loss of power. At least 3ms of

warning time is given. Following the loss of input power, the outputs are disabled when the bus voltage

drops below its operating threshold.

Figure 1

PFC MegaPAC-EL™ and

PFC MegaPAC-HPEL™

low-noise architecture

Input

Line Filter

Rectifier

Waveform

Sample

Current

Sample

Soft Start

Circuit

Boost Converter

High Voltage

DC Bus

QPAC #1

Power

Output

Power

Output

QPAC #2

PFC Control

QPAC #3

Power

Output

Customer

Interface

E/D Control

Enable/Disable Control

Fan

Current

Monitor

Housekeeping

Power

QPAC #8

Power

Output

Configuring and Reconfiguring MegaPACs

Most ConverterPACs of the same length can be inserted into any available slot of a MegaPAC chassis.

They can also be easily added, replaced or moved by sliding the assemblies in or out of a MegaPAC

chassis. For outputs greater than 200W, a driver QPAC™ and one or more booster ConverterPACs will

be used. For outputs greater than 600W, a driver FinQPAC™ and one or more booster ConverterPACs

will be used. Arrays of drivers and boosters should be configured so all boosters are placed in the slots

to the immediate right of the driver when looking at the output end of the MegaPAC.

Prior to removing or installing ConverterPACs, you must remove power from the MegaPAC

and wait five minutes. Failure to do so can result in personal injury or damage to the supply.

Take standard ESD precautions when handling ConverterPACs.

Removing ConverterPACs

ConverterPACs can be removed by loosening the captive screw at the base. Once this screw has been

loosened, the ConverterPAC will slide out of the chassis.

Once a ConverterPAC has been removed,

the empty slot MUST be filled with either another ConverterPAC or an airblock.

If the slot is left

empty, it will provide an airflow escape and cause failure to the power supply.

UG:119

Page 5

Recommended Resources

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Power supply noise filter circuit used in color television sets

Positive and negative voltage output voltage stabilizing circuit composed of 7800 series and 7900 series

Practical regulated power supply circuit diagram starting from 0V

Typical application circuit of TL1451

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